ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A173599

      Remove the oil filler cap.

  2. REMOVE OIL FILLER CAP GASKET

    1. A128159

      Remove the oil filler cap gasket.

  3. REMOVE ENGINE COVER JOINT

    1. A150847

      Remove the 2 engine cover joints.

  4. REMOVE SPARK PLUG

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR

    1. A173601

      Remove the 2 bolts and 2 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A173602

      Remove the 2 bolts, wire harness bracket and 2 camshaft timing oil control valves.

    2. Remove the 2 O-rings from the camshaft timing oil control valves.

  7. REMOVE CRANKSHAFT POSITION SENSOR

    1. A150855

      Remove the bolt and crankshaft position sensor.

  8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  9. REMOVE KNOCK SENSOR

    1. A152587

      Remove the bolt and knock sensor.

  10. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. A206180E04

      Using SST, remove the engine coolant temperature sensor and gasket.

      09817-33190

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A173472

      Remove the 13 bolts, seal washer and cylinder head cover.

    2. A165301

      Remove the 3 gaskets from the camshaft bearing cap.

      Note:

      As gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.

  12. REMOVE CYLINDER HEAD COVER GASKET

    1. A179166

      Remove the cylinder head cover gasket.

  13. REMOVE SPARK PLUG TUBE GASKET

    1. A179167

      Pry up the 4 claws of the ventilation baffle plate.

      Note:

      Do not deform the claws of the baffle plate more than necessary.

    2. Remove the 4 gaskets from the cylinder head cover.

      Tip:

      Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when installing new gaskets.

      Note:

      Be careful not to damage the cylinder head cover.

  14. REMOVE OIL FILTER CAP ASSEMBLY

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  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  16. REMOVE CRANKSHAFT PULLEY

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  17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  18. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  19. REMOVE TIMING CHAIN COVER OIL SEAL

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  20. REMOVE ENGINE MOUNTING BRACKET STUD BOLT

    Note:

    If a stud bolt is deformed or its threads are damaged, replace it.

  21. REMOVE WATER INLET HOUSING STUD BOLT

    Note:

    If a stud bolt is deformed or its threads are damaged, replace it.

  22. REMOVE WATER INLET HOUSING

    1. A150906

      Remove the 3 bolts, water inlet housing and gasket.

  23. REMOVE NO. 1 GENERATOR BRACKET

    1. A150905

      Remove the 4 bolts and generator bracket.

  24. REMOVE CHAIN TENSIONER SLIPPER

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  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  26. REMOVE CHAIN SUB-ASSEMBLY

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  27. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

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  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR KEY

    1. A150909E02

      Using a screwdriver, remove the 2 crankshaft timing gear keys.

      Table 1. Text in Illustration

      *1

      Protective Tape
      Tip:

      Tape the screwdriver tip before use.

      Note:

      Be careful not to damage the crankshaft.

  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  32. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  35. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

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  36. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY

    Click here

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  38. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    1. A173790

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

      Note:

      Slide only the upper part of the control actuator clip, as the straight pin may fall if the control actuator clip is completely removed.

    2. A209172

      Remove the bolt.

    3. A174268

      Using a screwdriver, lightly pry the control actuator connector to make a space between the continuously variable valve lift controller and camshaft housing.

      Note:

      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    4. A174269

      Using a magnet hand, remove the straight pin from the control actuator connector.

      Tip:

      The straight pin can be removed by utilizing the space between the continuously variable valve lift controller and camshaft housing to move the continuously variable valve lift controller so that there is no load on the straight pin.

    5. A206560E01

      Remove the continuously variable valve lift controller from the camshaft housing.

      Table 2. Text in Illustration

      *1

      Continuously Variable Valve Lift Controller Assembly

      *2

      Valve Lift Control Actuator Connector

      *3

      O-Ring

    6. Remove the O-ring from the continuously variable valve lift controller.

      Note:

      The O-ring may remain on the camshaft housing side. Be sure to always remove it.

    7. Remove the valve lift control actuator connector from the valve rocker shaft.

      Tip:

      There are two types of valve lift control actuator connectors. One type is removed by rotating the connector, and the other type can be removed without being rotated.

  39. REMOVE CAMSHAFT HOUSING STUD BOLT

    Note:

    If a stud bolt is deformed or its threads are damaged, replace it.

  40. REMOVE CAMSHAFT HOUSING STRAIGHT PIN

    Note:

    It is not necessary to remove a straight pin unless it is being replaced.

  41. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    1. A174965

      Remove the 16 valve rocker arms.

      Tip:

      Arrange the removed parts in the correct order.

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    1. U121328

      Remove the 16 valve lash adjusters from the cylinder head.

      Tip:

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE STEM CAP

    1. A150945

      Remove the 16 valve stem caps.

      Tip:

      Arrange the removed parts in the correct order.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  45. REMOVE CYLINDER HEAD GASKET

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  46. REMOVE VENTILATION VALVE SUB-ASSEMBLY

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  47. REMOVE OIL PAN DRAIN PLUG

    1. A150893

      Remove the drain plug and gasket.

  48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  49. REMOVE OIL PUMP ASSEMBLY

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  50. REMOVE STIFFENING CRANKCASE ASSEMBLY

    1. A150897

      Uniformly loosen and remove the 11 bolts.

    2. A150898E02

      Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block.

      Table 3. Text in Illustration

      *1

      Protective Tape
      Tip:

      Tape the screwdriver tip before use.

      Note:

      Be careful not to damage the contact surfaces of the crankcase and cylinder block.

  51. REMOVE NO. 1 TAPER SCREW PLUG

    1. A235913

      Remove the 2 No. 1 taper screw plugs.

  52. REMOVE STIFFENING CRANKCASE STUD BOLT

    Note:

    If a stud bolt is deformed or its threads are damaged, replace it.

  53. REMOVE STIFFENING CRANKCASE RING PIN

    Note:

    It is not necessary to remove a ring pin unless it is being replaced.

  54. REMOVE ENGINE REAR OIL SEAL

    1. A206144

      Remove the engine rear oil seal from the cylinder block.